Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D11/00—Producing optical elements, e.g. lenses or prisms
  • B29D11/00009—Production of simple or compound lenses
  • B29D11/00269—Fresnel lenses
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
  • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
  • B29C59/022—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D11/00—Producing optical elements, e.g. lenses or prisms
  • B29D11/00009—Production of simple or compound lenses
  • B29D11/00278—Lenticular sheets
  • B29D11/00288—Lenticular sheets made by a rotating cylinder
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
  • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
  • B41M3/00—Printing processes to produce particular kinds of printed work, e.g. patterns
  • B41M3/003—Printing processes to produce particular kinds of printed work, e.g. patterns on optical devices, e.g. lens elements; for the production of optical devices
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
  • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
  • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
  • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
  • B29C2035/0827—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using UV radiation
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
  • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
  • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
  • B29C35/0866—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation
  • B29C2035/0877—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation using electron radiation, e.g. beta-rays
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
  • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
  • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2009/00—Layered products
  • B29L2009/005—Layered products coated
  • B29L2009/008—Layered products coated metalized, galvanized

Definitions

• the invention generally relates to substrates for packaging and other applications and more particularly to fibrous or fabric substrates having Fresnel lens.
• Fresnel lenses are known to be used for packaging to make them more attractive.
• Fresnel lenses on substrates such as textile can be used as a unique packaging substrate or the cloth so obtained may be used to manufacture apparels such as fancy dresses.
• incorporation of Fresnel lenses with substrates such as textile has not been possible.
• the known methods of incorporating Fresnel lenses on various substrates as listed above are complex and expensive.
• the method of applying Fresnel lenses on substrates such as paper or paper board should be simpler, efficient, and cost-effective, allowing easier further processing. It is also desirable to provide an image or text as security feature to ensure originality of the product, over the Fresnel lens without obscuring the lens. It is also desired that the process should be simple so as to enable creation / transfer of Fresnel lenses on substrates such as textile.
• Fresnel lenses While incorporating Fresnel lenses over substrates using hot or cold stamping process known in the art, it has been observed that the edges on the periphery of the Fresnel lenses so incorporated appear to be broken, torn or having burrs and don't look sharp. Further, it is desired that the Fresnel lenses are incorporated in the form of a pattern or an array of small Fresnel lenses.
• the small Fresnel lenses in the array may be circular, triangular, star - shaped or any other geometrical shape or pattern.
• the present invention provides a process for providing Fresnel lenses on a substrate comprising the steps of coating the substrate with a curable coating, the curable coating being capable of curing using a radiation; embossing the curable coating with a Fresnel lens master, the Fresnel lens master imparting a pattern on the curable coating; and curing the curable coating using the radiation.
• the invention provides a process for providing at least one metalized Fresnel lens on a substrate by hot or cold foil stamping using a stamping punch and a stamping foil, wherein the size of the stamping punch is more than the size of the Fresnel lens.
• the invention also provides a fibrous or fabric substrate having Fresnel lenses with sharp edges prepared by a process comprising the steps of coating the substrate with a curable coating, the curable coating being capable of curing using a radiation; embossing the curable coating with a Fresnel lens master, the Fresnel lens master imparting a pattern on the curable coating; and curing the curable coating using the radiation.
• the invention provides a fibrous or fabric substrate having at least one Fresnel lens prepared by a process of hot or cold foil stamping comprising providing a stamping foil and a stamping punch having size more than the size of the Fresnel lens thereby ensuring sharp edges of the Fresnel lens.
• FIG. 1 is a flowchart depicting a process of making a Fresnel lens over a substrate, in accordance with an embodiment of the invention.
• FIG. 1 A is a flowchart depicting a process of making a substrate with Fresnel lens, in accordance with another embodiment of the invention.
• FIG. 2A illustrates the process of incorporating a Fresnel lens on the substrate by coating, embossing & curing, in accordance with an embodiment of the invention.
• FIG. 2B illustrates the process of incorporating a Fresnel lens on the substrate by hot or cold stamping, in accordance with an embodiment of the invention.
• FIG. 3 illustrates a cross sectional view and top view of a substrate having a metalized Fresnel lens, in accordance with an embodiment of the invention.
• FIG. 4A & 4B illustrates a process of transferring a latent image on
• Fresnel lens in accordance with an embodiment of the invention.
• FIG. 5 illustrates a process of laminating a reverse printed polymeric film with the substrate having a metalized Fresnel lens, in accordance with an embodiment of the invention.
• Figs. 6A-E illustrates various exemplary embodiments for providing the Fresnel lenses on roll of substrate and cut piece of substrate roll in accordance with an embodiment of the present invention.
• Various embodiments of the present invention provide a process for incorporating Fresnel lenses on a substrate.
• the invention also provides a substrate having a Fresnel lens made from such process.
• FIG. 1 is flow chart depicting process (100) for providing Fresnel lenses on a substrate (220) (shown in FIG. 2A and 2B), in accordance with an embodiment of the invention.
• the substrate (220) is selectively coated with a UV curable or E-beam curable coating (214) at locations where Fresnel lenses are required. It may also be contemplated that the coating with curable coating (214) may be performed all over the surface of the substrate (220).
• This coating (214) (shown in FIG. 2A) is provided either registered or unregistered with respect to a mark / printed matter on the substrate (220).
• the registration mark may be an eye mark, perforation, text, logo and the like on the substrate (220).
• Fresnel lenses (212) are registered with respect to an eye mark (310).
• the registration mark may also be printed at step (102) along with coating for Fresnel lens embossing. The said registration mark is subsequently used for the registration of embossing, printing, punching, holography, lamination with other substrates / film & other related processes.
• the coating (214) layer is embossed with a Fresnel lens master (240).
• the embossing is performed either registered or unregistered with respect to a mark / printed matter on the substrate.
• a single Fresnel lens is generated by machining on a metallic surface such as Steel, Copper, Nickel, Aluminum and the like or hard plastic such as Poly Carbonate and the like, using highly precise Computer Numerical Control (CNC) Machine.
• CNC Computer Numerical Control
• the single Fresnel lens so generated is recombined either manually or by UV recombining machine to form multiple embossed images on PET, PVC or Polycarbonate film.
• This parent master film can be used in various ways to configure Fresnel lens on substrate with curable coating (214):
• a metal master is obtained which is used to emboss polymer film to produce Fresnel lens master (240).
• the parent master film can be assembled on a cylinder and can be used for Fresnel lens embossing on the coated substrate but this is not economical.
• the parent master film so obtained is used to transfer the Fresnel lens embossing on to a cylinder through a UV curable coating method.
• One such method has been disclosed in patent application no. 4006/DEL/2012 titled "Method of making holographic embossing cylinder and apparatus for embossing hologram using holographic embossing cylinder on flexible packaging substrate".
• the thickness of the coating on the surface of the cylinder depends upon the parameters of the lens desired.
• the image on the single Fresnel lens master may be negative or positive to obtain Fresnel lenses of desired generation (+ve/-ve) on the substrate (220).
• a cylinder (230) carrying the Fresnel lens master (240) transfers the embossed image on the curable layer (coating 214) of about 5 ⁇ 350 microns on the substrate (220), as illustrated in FIG. 2A. It may be apparent that a single Fresnel lens or a pattern of Fresnel lenses may be registered or unregistered applied to the substrate, using a Fresnel lens master (240) prepared accordingly.
• the said pattern of Fresnel lenses on a roll of substrate may include:
• the array of the Fresnel lenses is shown in figure 6B as an exemplary embodiment of the present invention; and (c) a group or cluster of the Fresnel lenses.
• the said group or cluster may comprise a predetermined number of the Fresnel lenses and predefined shape and size of the Fresnel lenses.
• the shape or the size of one or more Fresnel lenses provided in the group or cluster may be identical or different from one another.
• the group or cluster may also comprises one or more Fresnel lenses wherein the Fresnel lens may be a complete Fresnel lens or randomly cut portion(s) of Fresnel lenses or a combination thereof.
• the group or cluster may be located at predetermined locations on the substrate roll.
• the group or cluster of Fresnel lenses on the substrate roll is shown in figure 6C as an exemplary embodiment of the present invention.
• the pattern of the Fresnel lenses may include: (a) a predetermined array of the Fresnel lenses wherein the said
• Fresnel lenses are provided at predefined locations on the cut pieces of substrate.
• the array of the Fresnel lenses on the cut piece of substrate is shown in figure 6D as an exemplary embodiment of the present invention; and (b) a group or cluster of the Fresnel lenses.
• the said group or cluster may comprise a predetermined number of the Fresnel lenses and predefined shape and size of the Fresnel lenses.
• the shape and / or the size of one or more Fresnel lenses provided in the group or cluster may be identical or different from one another.
• the group or cluster may also comprises one or more Fresnel lenses wherein the Fresnel lens may be a complete Fresnel lens or randomly cut portion(s) of Fresnel lenses or a combination thereof.
• the group or cluster may be located at predetermined locations on the cut pieces of substrate.
• the group or cluster of Fresnel lenses on the cut piece of substrate is shown in figure 6E as an exemplary embodiment of the present invention.
• the embossed curable layer is cured using UV or E- beam. Curing the coating may be performed using one of:
• UV can only be done from the side of coating if the substrate is translucent or opaque or b.
• E-beam may be done from either side of the substrate of any type
• the embossed and cured surface of the substrate (220) is metalized with a metallic layer either selectively over the embossed and cured Fresnel lenses or over full surface of the substrate (220) to get a mirror-like lens effect.
• the metallic layer includes any of Aluminum, Aluminum Oxide, Zinc Sulphide, Silicon Oxide, Silver, Gold, Copper, Chrome, Silicon Monoxide, Silicon Dioxide, Magnesium Fluoride, Titanium Dioxide, Tin Tungsten Oxide and Indium Tin Oxide or any other suitable metal, or their combination.
• metalizing may be performed either:
• Fresnel lenses (212) are shown in enlarged cross- sectional view of FIG. 3.
• the top view shows the three metalized Fresnel lenses (212) on substrate (220) or b. All over the surface of the substrate (220) including embossed Fresnel lenses but excluding any registration mark, if present.
• process (100) includes the step of providing a protective lacquer coat over the metallization provided at step 108.
• step (102A) is performed instead of step (102) to step (108).
• This alternate embodiment has been shown as process (100A) in the form of another flowchart in FIG. 1A.
• at step (102A) at least one or more metalized Fresnel lenses (212B) are hot or cold foil stamped using a punch (250) and hot or cold stamping foil (260), registered or unregistered, on the substrate (220) such as textile, coated / uncoated paper or paper board as shown in FIG. 2B.
• the Fresnel lens stamping may be performed on a roll of substrate web or cut pieces of substrate, on flat bed stamping machine having single / multiple stamping punches or by a stamping roller having single / multiple stamping punches, duly registered or unregistered.
• the stamping machines used for stamping may or may not have foil saving systems.
• a periphery of a stamping punch lies outside a periphery of the Fresnel lens, i.e., the size of the stamping punch (250) is more than the size of the lens (212B) and preferably only marginally more than the lens (212B) so that the detachment from stamping foil (260) during stamping happens outside the lens periphery. Bigger size of punch (250) also provides wider registration tolerances during stamping.
• Metallization at step (108), if done selectively, is done on the surface of the substrate (220) at least up to or beyond the periphery of the Fresnel lens (212B).
• the bigger size of the punch than the Fresnel lens ensures that the tearing happens outside the embossed Fresnel lens when the stamping foil (260) is peeled off the substrate after stamping ensuring that the problem of broken edges of the stamped lens.
• the broken edges or burrs on the edges appear when the stamping punch edges fall over the embossed circular rings of the Fresnel lens and the tearing happens somewhere over the rings.
• steps (1 10-116) of process (100) and (100A) are similar and for the sake of brevity description with reference to only process (100) is provided.
• a latent image / text is configured over the Fresnel lens.
• This latent image is not visible to a naked eye and only visible under special conditions such as under specified light (UV), using a polarizer, viewing at certain angle, on application of some chemical or steam / moisture and the like.
• a layer of 2-15 micron coating of a release coating such as wax or Silicon or synthetic natural oil or polymer based which is transparent, is applied to one surface of a flexible polymeric film (410) (FIG.
• a latent image (412) in the form of a thin transparent layer is configured over the release coating on the surface of the flexible polymeric film (410).
• a transparent thin layer of suitable adhesive is applied over the latent image (412).
• the latent image (412) may be any text, alphanumeric character or a picture or pattern or a combination of these, etc. For example, as shown in FIG.4B, the latent image (412) is text.
• the flexible polymeric film (410) with latent image (412) and a layer of adhesive, so obtained is laminated with the substrate (220), as shown in FIG. 4A.
• the laminate may then be cured for a specified period of time.
• the flexible polymeric film (410) is removed / peeled-off, as shown in FIG. 4A and the latent image (412) configured thereon is transferred over the Fresnel lens (212) on the substrate (220).
• the latent image (412) transferred over the substrate may or may not be registered with any printing or marking.
• FIG. 4B illustrates that the latent image (412) is visible only through a special device such as a circular polarizer (420).
• the latent image may also be provided using printing with ink visible in UV light / or holography.
• the process (100) optionally includes providing printing on the substrate (220).
• substrate (220) is optionally printed leaving Fresnel lenses.
• Printing may be performed by Screen printing, rotogravure printing, offset printing, Flexographic, Digital printing and the like.
• FIG. 5 illustrates a process of laminating a reverse printed polymeric film (510) with the substrate (220) having metalized Fresnel lenses (212), in accordance with an embodiment of the invention.
• Film (510) has opaque printed areas (520) and unprinted transparent areas (512), which are registered with the Fresnel lens (212) on the substrate (220) while laminating, through which the lenses remain visible.
• the substrate is laminated with polymeric film / laminate and surface printing is performed over the outside surface of the film. Further, subsequently, optionally UV or E-beam curable coating is applied on selective or full surface of the substrate to protect and impart gloss to the surface printing.
• the substrate (220) may be a fibrous substrate such as coated or uncoated paper or paper board, synthetic fibrous substrates and the like, and textile, fabric or cloth and the like.
• process (100) and (100A) have been described sequentially above. However, it should be appreciated that sequence of the steps of process (100) and (100A) can be changed if required and possible.

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• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Mechanical Engineering (AREA)
• Health & Medical Sciences (AREA)
• Ophthalmology & Optometry (AREA)
• Printing Methods (AREA)
• Chemical Or Physical Treatment Of Fibers (AREA)
• Shaping Of Tube Ends By Bending Or Straightening (AREA)
• Application Of Or Painting With Fluid Materials (AREA)

Applications Claiming Priority (2)

Publications (2)

Family

ID=54395836

Family Applications (1)

Country Status (2)

Citations (7)

• 2014
  • 2014-09-01 IN IN2473DE2014 patent/IN2014DE02473A/en unknown
• 2015
  • 2015-08-06 WO PCT/IN2015/000315 patent/WO2016035093A1/en active Application Filing

Patent Citations (8)

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